Vacuum generating system for an appliance incorporating a vacuum insulated structure

ABSTRACT

An appliance includes an outer wrapper and an inner liner placed within the outer wrapper and spaced apart from the outer wrapper to define an insulating space. A trim breaker extends between the inner liner and the outer wrapper to define a structural cabinet. The trim breaker defines a front face of the cabinet. The trim breaker defines a gas conduit disposed within a wall of the structural cabinet proximate the insulating space. The gas conduit is adapted to define selective communication between the insulating space and an exterior of the structural cabinet. An insulating material is disposed within the insulating space, wherein the gas conduit is substantially free of the insulating material.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a divisional of U.S. patent application Ser.No. 16/304,393 filed Nov. 26, 2018, entitled VACUUM GENERATING SYSTEMFOR AN APPLIANCE INCORPORATING A VACUUM INSULATED STRUCTURE, now U.S.Pat. No. 10,830,526, which is a national stage of InternationalApplication No. PCT/US2016/053711 filed Sep. 26, 2016, entitled VACUUMGENERATING SYSTEM FOR AN APPLIANCE INCORPORATING A VACUUM INSULATEDSTRUCTURE, the entire disclosures of which are hereby incorporatedherein by reference.

FIELD OF THE DEVICE

The device is in the field of vacuum insulated structures forappliances, and more specifically, an air movement system disposedwithin the appliance for generating a vacuum within a vacuum insulatedstructure.

SUMMARY

In at least one aspect, an appliance includes an outer wrapper and aninner liner placed within the outer wrapper and spaced apart from theouter wrapper to define an insulating space. A trim breaker extendsbetween the inner liner and the outer wrapper to define a structuralcabinet. The trim breaker defines a front face of the cabinet. The trimbreaker defines a gas conduit disposed within a wall of the structuralcabinet proximate the insulating space. The gas conduit is adapted todefine selective communication between the insulating space and anexterior of the structural cabinet. An insulating material is disposedwithin the insulating space, wherein the gas conduit is substantiallyfree of the insulating material.

In at least another aspect, an appliance includes a structural cabinethaving an interior cavity defined by an inner liner, an outer wrapperand a trim breaker that extends between the inner liner and the outerwrapper. A gas conduit is defined within an interior cavity of thestructural cabinet, wherein the interior cavity also includes aninsulation space that is partially separated from the gas conduit by afilter member. A plurality of gas valves are selectively operablebetween open and closed positions, the open position defined by fluidcommunication between an exterior of the structural cabinet and theinsulating space via the gas conduit, the closed position defined by theinterior cavity being hermetically sealed at the plurality of valves.

In at least another aspect, a method of forming a vacuum insulatedstructure includes steps of coupling a trim breaker to an inner linerand an outer wrapper to define a structural cabinet and an insulatingspace therein, the trim breaker defining an interior gas conduit that isat least partially separated from the insulating space. An insulatingmaterial is disposed within the insulating space. A plurality of gasvalves are attached to the structural cabinet. The plurality of gasvalves are in selective communication with the insulating space via theinterior gas conduit. A vacuum chamber is placed around at least aportion of the structural cabinet such that the plurality of gas valvesare disposed within the vacuum chamber. Gas is expressed from the vacuumchamber to define a first gas pressure proximate the exterior of thestructural cabinet and around the plurality of gas valves. The first gaspressure is less than a second gas pressure defined within theinsulating space and the gas conduit, thereby defining an open positionof the plurality of gas valves. Gas is expressed from the insulatingspace through the plurality of gas valves in the open position via thegas conduit and into the vacuum chamber, wherein the expressed gas isfurther expressed from the vacuum chamber, wherein as the gas isexpressed through the gas conduit, the insulating material is maintainedin the insulating space. The plurality of gas valves are placed in theclosed position by defining a substantially equalized pressure withinthe vacuum chamber and the insulating space, wherein the first gaspressure is approximately equal to the second gas pressure. Gas isreturned to the vacuum chamber such that the first gas pressure isgreater than the second gas pressure, and wherein the plurality of gasvalves are maintained in the closed position. The vacuum chamber and thestructural cabinet are separated.

These and other features, advantages, and objects of the present devicewill be further understood and appreciated by those skilled in the artupon studying the following specification, claims, and appendeddrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a schematic perspective view of a structural cabinet for anappliance incorporating an aspect of the vacuum generating system;

FIG. 2 is a schematic perspective view of a structural cabinet for anappliance incorporating another aspect of the vacuum generating system;

FIG. 3 is a schematic illustration exemplifying a gas valve used withinan aspect of the vacuum generating system;

FIG. 4 is a cross-sectional view of a trim breaker incorporated withinan aspect of the structural cabinet and incorporating portions of thevacuum generating system;

FIG. 5 is a schematic cross-sectional view of a wall of the structuralcabinet incorporating an aspect of the vacuum generation system;

FIG. 6 is a perspective view of a structural cabinet incorporating anaspect of the vacuum generating system incorporating a plurality of gasvalves within a trim breaker;

FIG. 7 is a schematic cross-sectional view of the gas valve of FIG. 6illustrating the gas valve in a closed position;

FIG. 8 is a cross-sectional view of the gas valve of FIG. 7 illustratingthe gas valve in an open position;

FIG. 9 is a schematic cross-sectional view of an aspect of the gasgenerating system with a structural cabinet entirely disposed within avacuum chamber, and the vacuum generating system operating to place thegas valves in an open position;

FIG. 10 is a schematic cross-sectional view of the vacuum chamber ofFIG. 9 showing the gas generating device creating an equalized low airpressure within the vacuum chamber and within an insulating space of thestructural cabinet to place the gas valves in a closed position;

FIG. 11 is a schematic cross-sectional view of the vacuum chamber ofFIG. 10 illustrating the vacuum generation system returning air to thevacuum chamber while maintaining an at least partial vacuum within theinsulating space of the structural cabinet and maintaining the gasvalves in a closed position;

FIG. 12 is a partially exploded perspective view of an aspect of avacuum frame used to generate an at least partial vacuum around a trimbreaker of a structural cabinet;

FIG. 13 is a perspective view of a vacuum frame attached to the frontedge of the structural cabinet of FIG. 12;

FIG. 14 is a cross-sectional view of the structural cabinet of FIG. 13taken along line XIV-XIV; and

FIG. 15 is a schematic flow diagram illustrating a method for forming avacuum insulated structure.

DETAILED DESCRIPTION OF EMBODIMENTS

For purposes of description herein the terms “upper,” “lower,” “right,”“left,” “rear,” “front,” “vertical,” “horizontal,” and derivativesthereof shall relate to the device as oriented in FIG. 1. However, it isto be understood that the device may assume various alternativeorientations and step sequences, except where expressly specified to thecontrary. It is also to be understood that the specific devices andprocesses illustrated in the attached drawings, and described in thefollowing specification are simply exemplary embodiments of theinventive concepts defined in the appended claims. Hence, specificdimensions and other physical characteristics relating to theembodiments disclosed herein are not to be considered as limiting,unless the claims expressly state otherwise.

As illustrated in FIGS. 1-6, reference numeral 10 generally refers to avacuum generating system for drawing gas 12, such as air, from aninsulating space 14 defined within a structural cabinet 16 for anappliance 18, and maintaining an at least partial vacuum 20 within theinsulating space 14. According to the various embodiments, an appliance18 can include an outer wrapper 22 and an inner liner 24 that is placedwithin the outer wrapper 22. The inner liner 24 and outer wrapper 22 arespaced apart from one another to define the insulating space 14therebetween. A trim breaker 26 extends between the inner liner 24 andthe outer wrapper 22 to define the structural cabinet 16 with theinsulating space 14 defined therein. The trim breaker 26 defines a frontface 28 of the structural cabinet 16, where the front face 28 of thestructural cabinet 16 defines various apertures for refrigeratedcompartments 30 within the structural cabinet 16. The trim breaker 26can extend along the front face 28 of the sidewalls 32, top wall 34 andbottom wall 36 of the structural cabinet 16. Additionally, the frontface 28 can extend along a mullion 38 that extends across an interiorrefrigerated compartment 30 of the structural cabinet 16 to definemultiple refrigerated compartments 30. It is contemplated that the trimbreaker 26 can define a gas conduit 40 disposed proximate the front face28 of the structural cabinet 16 proximate the insulating space 14. Thegas conduit 40 can be adapted to define a selective communicationbetween the insulating space 14 and an exterior 42 of the structuralcabinet 16. An insulating material 44 is disposed within the insulatingspace 14, where the gas conduit 40 is substantially free of theinsulating material 44.

Referring again to FIGS. 1-8, to further define the vacuum generatingsystem 10, at least one gas valve 50 is disposed within a portion of thetrim breaker 26. The at least one gas valve 50 is operable between openand closed positions 52, 54. The gas valve 50 can be a passivelyoperated valve or can be a valve that is manually crimped and closed.The open position 52 is defined by a fluid communication existingbetween the insulating space 14 and the exterior 42 of the structuralcabinet 16 via the gas conduit 40. In this manner, the gas valve 50 isadapted to extend at least partially into the gas conduit 40 to allowfor movement of air from the insulating space 14 through the gas conduit40 and out of the gas valve 50, when the gas valve 50 is in the openposition 52. The closed position 54 of the gas valve 50 is defined bythe gas conduit 40 and the insulating space 14 being hermetically sealedrelative to the exterior 42 of the structural cabinet 16. In thismanner, the closed position 54 of the various gas valves 50substantially prevents, or totally prevents, the flow of gas 12 from theinsulating space 14 and the gas conduit 40 to the exterior 42 of thestructural cabinet 16. In this manner, the various gas valves 50 in theclosed position 54 serve to maintain an at least partial vacuum 20within the insulating space 14 and the gas conduit 40.

Referring again to FIGS. 3-11, the open position 52 of the various gasvalves 50 is defined by, or can be achieved by, the vacuum generatingsystem 10 defining a first gas pressure 60 present proximate theexterior 42 of the structural cabinet 16. Simultaneously, a second gaspressure 62 is present within the insulating space 14 and the gasconduit 40. This second gas pressure 62 within the insulating space 14and the gas conduit 40 is less than the first gas pressure 60 around theexterior 42 of the structural cabinet 16. In this manner, the highersecond gas pressure 62 within the insulating space 14 and the gasconduit 40 causes an outward force interior that pushes a portion of thegas valve 50 outward to allow for the expression of gas 12 from theinsulating space 14, through the gas conduit 40, and out of the gasvalve 50 that is now in the open position 52. Accordingly, drawing airfrom a vacuum chamber 64 through the use of a vacuum pump 66 also servesto draw air from the insulating space 14 via the gas conduit 40 andthrough the various gas valves 50 in the open position 52.

Referring again to FIGS. 5-11, the expression of gas from the vacuumchamber 64 and from within the insulating space 14 of the structuralcabinet 16 eventually results in a substantially equalized pressure 70between the first and second gas pressures 60, 62 present within thevacuum chamber 64 and the insulating space 14, respectively. Once thefirst and second gas pressures 60, 62 are substantially equalized, orare equalized, the outward force is removed and the gas valves 50 definethe closed position 54. It is contemplated that the resting state of theplurality of gas valves 50 can be in the closed position 54 such thatthe gas valves 50 are adapted to move to the closed position 54 when thefirst and second gas pressures 60, 62 are equalized.

Referring again to FIGS. 3-11, once the gas valves 50 are moved to theclosed position 54, the vacuum generating system 10 can be deactivatedand air can be returned to the vacuum chamber 64 and around the exterior42 of the structural cabinet 16. In this manner, the vacuum chamber 64has the first air pressure that is consistent with the typicalatmospheric pressure surrounding the vacuum chamber 64. Because theplurality of gas valves 50 have been moved to the closed position 54,after substantially all of the air was removed from the vacuum chamber64, the various gas valves 50 remain in the closed position 54 when airis reintroduced into the vacuum chamber 64. The reintroduced airgenerates an inward force 80 that pushes a portion of the gas valve 50against the exterior 42 of the structural cabinet 16. In this manner,the air that is returned into the vacuum chamber 64 is not permitted toenter into the insulating space 14 since the various gas valves 50 arenow in the closed position 54 in the insulating space 14 and gas conduit40 are each hermetically sealed from areas exterior 42 to the structuralcabinet 16. Accordingly, the closed position 54 that reaches the variousgas valves 50 is defined by the second gas pressure 62 present withinthe insulating space 14 and the gas conduit 40 being equal to or lessthan the first gas pressure 60 that is present around the exterior 42 ofthe structural cabinet 16.

Referring again to FIGS. 4-8, the at least one gas valve 50 can be inthe form of an umbrella valve 90, where a portion of the umbrella valve90 extends through at least a portion of the exterior 42 of thestructural cabinet 16. In such an embodiment, the gas valve 50 includesan operable flap 92 that is operable to define the open and closedpositions 52, 54 of the gas valve 50. The operable flap 92 is adapted toengage the exterior 42 of the structural cabinet 16 when in the closedposition 54. The operable flap 92 is further adapted to deflect awayfrom the structural cabinet 16 when in the open position 52 to allow forthe release of air from the insulating space 14 via the gas conduit 40and through the gas valves 50 in the open position 52. It iscontemplated that the operable flap 92 can extend over one or moreventing apertures 94 defined within the exterior 42 of the structuralcabinet 16. When the gas valves 50 are in the closed position 54, theoperable flap 92 covers these venting apertures 94 to hermetically sealthe venting apertures 94 from allowing the release of gas 12 from withinthe insulating space 14 and the gas conduit 40. When the gas valve 50 ismoved to the open position 52, the operable flap 92 deflects away fromthe surface of the structural cabinet 16 and defines a fluidcommunication between the insulation space and the exterior 42 of thestructural cabinet 16 via the gas conduit 40 and the various gas valves50.

According to the various embodiments, the gas conduit 40, which isdefined within the interior cavity 100 of the structural cabinet 16 canbe disposed proximate the trim breaker 26, the inner liner 24 or theouter wrapper 22. Accordingly, the gas conduit 40 can define asubstantially continuous conduit that extends through various portionsof the interior cavity 100 proximate the insulating space 14 of thestructural cabinet 16. In this manner, when the vacuum generating system10 draws air from the vacuum chamber 64, air is moved from theinsulating space 14 and into the gas conduit 40. Again, the gas conduit40 extends substantially continuously or continuously through theinterior cavity 100 of the structural appliance 18 to allow for thesubstantially free and efficient movement of gas 12 from the insulatingspace 14 and through the gas valves 50 via the gas conduit 40. The gasconduit 40 can be defined by various integral structures that are formedwithin the trim breaker 26, the inner liner 24, the outer wrapper 22, orcombinations thereof such that the gas conduit 40 may be adapted to runthrough various portions of the interior cavity 100 of the structuralcabinet 16. By way of example, and not limitation, FIGS. 4 and 5illustrate a gas conduit 40 that is integrally formed within a portionof the trim breaker 26 such as a filter recess 110. In such anembodiment, the gas conduit 40 runs within the interior cavity 100 ofthe structural cabinet 16 proximate the front face 28 of the structuralcabinet 16. Again, it is contemplated that the gas conduit 40 can be inthe form of a single continuous air moving channel that connects orsubstantially connects each of the gas valves 50 with one another suchthat each of the gas valves 50 are also placed in communication with oneanother via the gas conduit 40.

Referring again to FIGS. 2-8, it is contemplated that the gas conduit 40can be at least partially defined by a filter member 120 that defines aboundary 122 between the insulating space 14 and the gas conduit 40. Inthis manner, the filter member 120 can be disposed along an outersurface of the gas conduit 40 to maintain the gas conduit 40 to be freeof the insulating material 44. In other words, in order to allow for thesubstantially free movement of air through the gas conduit 40, thefilter member 120 prevents the insulating material 44 from infiltratingthe gas conduit 40 that might serve to clog or impede the flow of airthrough the gas conduit 40 and to the various fluid valves during theexpression of gas 12 from the insulating space 14. It is contemplatedthat the filter member 120 can be in the form of a planar screen 130that extends across the filter recess 110 defined within the trimbreaker 26, or defined within the inner liner 24 and/or outer wrapper22. It is further contemplated that the filter member 120 can be in theform of a filter tube 132 that is disposed within the filter recess 110of the trim breaker 26, or other component of the structural cabinet 16.In such an embodiment, the filter tube 132 and the filter recess 110cooperate to define the gas conduit 40.

It is contemplated that the filter member 120, whether a planar screen130, such as a mesh barrier, or filter tube 132, can include a pluralityof filter apertures that are sized to be generally smaller than theparticle size of the insulating material 44. Accordingly, the filtermember 120 can serve to contain the insulating material 44 within theinsulating space 14 and prevent or substantially prevent theinfiltration of the insulating material 44 within the gas conduit 40. Itis also contemplated that the mesh size of the filter member 120 can beadapted to be smaller than the vent apertures defined within theexterior surface of the structural cabinet 16 proximate each of thevalves. Accordingly, where insulating material 44 does infiltrate thegas conduit 40, such particles of insulating material 44 may be smallenough to pass through the vent apertures and out from the gas conduit40, such that the free or substantially free movement of gas 12 throughthe gas conduit 40 can be maintained during formation of the vacuuminsulated structure by the vacuum generating system 10.

Referring again to FIGS. 1-11, it is contemplated that the first andsecond gas pressures 60, 62 that serve to operate the various gas valves50 between the open and closed positions 52, 54 can be generated by avacuum pump 66 that is placed in communication with the at least one gasvalve 50. Accordingly, the vacuum pump 66 is adapted to selectivelygenerate and dissipate an at least partial vacuum 20 within the vacuumchamber 64 that is selectively positioned at least proximate the frontface 28 of the structural cabinet 16 and potentially around the entirestructural cabinet 16. Accordingly, as discussed above, the expressionof air from the structural cabinet 16 places the various gas valves 50in the open position 52. Once the first and second gas pressures 60, 62within the vacuum chamber 64 and inside the insulating space 14,respectively, are equalized, the gas valves 50 are moved to the closedposition 54. As discussed above, once air is reintroduced into thevacuum chamber 64, the gas valves 50 are maintained in the closedposition 54 such that the at least partial vacuum 20 within theinsulating space 14 can be maintained when air is returned to the vacuumchamber 64.

Referring now to FIGS. 1-14, it is contemplated that the appliance 18can include the structural cabinet 16 that has the interior cavity 100defined by the inner liner 24, the outer wrapper 22 and the trim breaker26 that extends between the inner liner 24 and outer wrapper 22. Asdiscussed above, the gas conduit 40 is defined within the interiorcavity 100 of the structural cabinet 16. The interior cavity 100 alsoincludes an insulating space 14 that is partially separated from the gasconduit 40 by the filter member 120. The plurality of gas valves 50 areselectively operable between open and closed positions 52, 54. Asdiscussed above, the open position 52 is defined between fluidcommunication between the exterior 42 of the structural cabinet 16 andthe insulating space 14 via the gas conduit 40. The closed position 54of the gas valves 50 is defined by the interior cavity 100 beinghermetically sealed from the exterior 42 of the structural cabinet 16 atthe plurality of gas valves 50. As discussed above, the gas conduit 40can be defined within a portion of the trim breaker 26. It is alsocontemplated, in various embodiments, that the various conduits can bedefined within portions of the inner liner 24 and outer wrapper 22. Ineach of these embodiments, it is contemplated that the gas conduit 40includes the filter member 120 that serves to contain the insulatingmaterial 44 within the insulating space 14 and substantially preventsthe infiltration of the insulating material 44 into the gas conduit 40.

Referring again to FIGS. 6-8 and 12-14, it is contemplated that thevacuum chamber 64 can be in the form of a vacuum frame 140 that engagesthe structural cabinet 16 proximate the front face 28 of the structuralcabinet 16. In such an embodiment, the vacuum frame 140 can attach tothe front face 28, and may at least partially extend around portions ofthe front face 28 to securely engage the structural cabinet 16. Wherethe vacuum frame 140 is utilized, the vacuum frame 140 expresses gas 12from an area proximate the front face 28 of the structural cabinet 16 todefine the first air pressure at the exterior 42 of the structuralcabinet 16 to be less than the second air pressure, thereby moving thevarious gas valves 50 to the open position 52. While the gas valves 50are in the open position 52, gas 12 is expressed from the insulatingspace 14 and through the gas valves 50 in the open position 52 via thegas conduit 40. As discussed above, once the first and second gaspressures 60, 62 define an equalized pressure 70 through the expressionof gas 12 from the vacuum chamber 64 and the insulating space 14, thevarious gas valves 50 move to the closed position 54. Once in the closedposition 54, the vacuum frame 140 allows air to return to the vacuumchamber 64 and around the exterior surface of the structural cabinet 16proximate the front face 28. Because the first air pressure is greaternow than the second air pressure, the pressure differential between theexterior 42 of the structural cabinet 16 and the insulating space 14pushes the operable flap 92 against the exterior 42 of the structuralcabinet 16 and maintains the hermetic seal at the various gas valves 50to prevent infiltration of gas 12 into the insulating cavity via the gasconduit 40. Once air is returned to the vacuum chamber 64 within thevacuum frame 140, the vacuum frame 140 can be removed and the gas valves50 continue to be maintained in the closed position 54 to maintain theat least partial vacuum 20 within the insulating space 14.

According to the various embodiments, the use of the vacuum frame 140versus the fully enclosing vacuum chamber 64 as part of the vacuumgenerating system 10 can depend upon various factors that can include,but are not limited to, the placement of the various gas valves 50 andthe path of the gas conduit 40, the size of the structural cabinet 16,the configuration of the various walls of the structural cabinet 16, thethickness of the walls of the structural cabinet 16, the composition ofthe insulating material 44 within the structural cabinet 16,combinations thereof, and other similar factors. Typically, where all ofthe gas valves 50 are disposed in the front face 28 of the structuralcabinet 16, the use of the vacuum frame 140 can be advantageous sinceall of the gas valves 50 are substantially within the same verticalplane along the front face 28 of the structural cabinet 16.Alternatively, where the various gas valves 50 are disposed within thetrim breaker 26, the inner liner 24 and outer wrapper 22, the use of thefully enclosing vacuum chamber 64 may be more advantageous due to themore complex placement of the various gas valves 50.

It is also contemplated that various sections of the filter member 120may be extended into interior portions of the insulating space 14. Inthis manner, portions of the gas conduit 40 may extend distal from thevarious gas valves 50 and may be run into more remote sections of theinsulating space 14 to allow for the more efficient movement of the gas12 from the insulating space 14, through the gas conduit 40, and to thevarious gas valves 50 of the vacuum generating system 10. These branchsections 150 (shown in FIG. 2) of the filter member 120 can be runthrough interior portions of each of the walls of the structural cabinet16, along corners of the structural cabinet 16, along inward surfaces ofthe inner liner 24 and/or outer wrapper 22 and other locations to allowfor the more efficient flow of gas 12 from the insulating space 14 tothe gas conduit 40. It is contemplated that the use of these branchsections 150 of the gas conduit 40 may need to be limited in order toprevent the placement of the branch sections 150 from detracting fromthe insulating functions of the structural cabinet 16. To prevent such acondition, the branch sections 150 of the gas conduit 40 may be of afiner diameter filter tube 132 such that the various branch sections 150occupy only a very minimal space within the various sections of theinsulating space 14 of the structural cabinet 16, while also allowingfor the efficient movement of gas 12 through the insulating space 14.

Referring now to FIGS. 1-15, having described the various embodiments ofthe vacuum generating system 10, a method 400 is disclosed for forming avacuum insulated structure within a structural cabinet 16. According tothe method 400, a trim breaker 26 is coupled to an inner liner 24 and anouter wrapper 22 to define a structural cabinet 16 and an insulatingspace 14 disposed therein (step 402). It is contemplated that the trimbreaker 26 can define the interior gas conduit 40 that is at leastpartially separated from the insulating space 14. During the formationof the structural cabinet 16, an insulating material 44 can be disposedwithin the insulating space 14 (step 404). Various insulating materials44 can include, but are not limited to, vacuum insulated panels,microspheres, nanospheres, fibrous insulating material, varioussilica-based materials, combinations thereof and other similarinsulating materials. The plurality of gas valves 50 are attached to thestructural cabinet 16, where each of the gas valves 50 is adapted to bein selective communication with the insulating space 14 via the interiorgas conduit 40 (step 406). It is contemplated that the plurality of gasvalves 50 can be set within a portion of the trim breaker 26 and atleast partially extend into the gas conduit 40 defined within the trimbreaker 26. In such an embodiment, it is contemplated that the trimbreaker 26 may be an injection molded member that is injection moldedaround the various gas valves 50. It is also contemplated that thevarious gas valves 50 can be separately inserted into various portionsof the trim breaker 26 after formation of the trim breaker 26. Asdiscussed above, the various gas valves 50 can also be disposed withinportions of the inner liner 24/or the outer wrapper 22 where the gasconduit 40 extends through portions of the inner liner 24 and outerwrapper 22 of the structural cabinet 16. After the structural cabinet 16is formed, a vacuum chamber 64 is placed around at least a portion ofthe structural cabinet 16, such that the plurality of gas valves 50 aredisposed within the vacuum chamber 64 (step 408). As discussed above,where the various gas valves 50 are disposed only along the front face28 of the structural cabinet 16, the vacuum chamber 64 may be in theform of a vacuum frame 140 that attaches to the front face 28 of thestructural cabinet 16.

Alternatively, where the various gas valves 50 are disposed aroundportions of the structural cabinet 16, such as in the trim breaker 26,in the inner liner 24 and/or in the outer wrapper 22, the entirestructural cabinet 16 may be enclosed within a surrounding vacuumchamber 64. Once the vacuum chamber 64 is properly positioned withrespect to the various gas valves 50, gas 12 can be expressed from thevacuum chamber 64 to define the first gas pressure 60 proximate theexterior 42 of the structural cabinet 16 and around the plurality of gasvalves 50 (step 410).

As discussed above, where this first gas pressure 60 is less than asecond gas pressure 62 defined within the insulating space 14 and a gasconduit 40, the various gas valves 50 are operated to define an openposition 52 of the gas valves 50. As gas 12 is expressed from the vacuumchamber 64 to place the various valves in the open position 52, gas 12is also expressed from the insulating space 14 through the plurality ofgas valves 50 in the open position 52 via the gas conduit 40 and intothe vacuum chamber 64 (step 412). In this manner, the expressed gas 12from the insulating space 14 is further expressed from the vacuumchamber 64.

According to the various embodiments, as gas 12 is expressed through thegas conduit 40, the filter member 120 serves to maintain the insulatingmaterial 44 within the insulating space 14 and substantially preventinfiltration of the insulating material 44 into the gas conduit 40.After sufficient gas 12 is expressed from the vacuum chamber 64 and theinsulating space 14, the plurality of gas valves 50 are placed in theclosed position 54 that is defined by a substantially equalized pressure70 within the vacuum chamber 64 outside the structural cabinet 16 andthe insulating space 14 (step 414). Accordingly, the first gas pressure60 is approximately equal to the second gas pressure 62 to define thesubstantially equalized gas pressure that allows the gas valves 50 tomove to the closed position 54. After the gas valves 50 are moved to theclosed position 54 and the insulating space 14 and gas conduit 40 arehermetically sealed from the exterior 42 of the structural cabinet 16 bythe gas valves 50 in the closed position 54, gas 12 is returned to thevacuum chamber 64 (step 416). When gas 12 is returned to the vacuumchamber 64, the first gas pressure 60 now becomes greater than thesecond gas pressure 62 and the plurality of gas valves 50 are maintainedin the closed position 54 by the lower second gas pressure 62 within theinsulating cavity of the gas conduits 40. The lower second gas pressure62 within the interior cavity 100 of the structural cabinet 16 draws theoperable flap 92 inward and toward the exterior 42 of the structuralcabinet 16 to maintain a hermetic seal at each of the gas valves 50.

According to the various embodiments, the use of the vacuum generatingsystem 10 can assist in the distribution of the insulating material 44throughout the insulating space 14. It is contemplated that the gasconduit 40 can be used during the process of disposing the insulatingmaterial 44 within the insulating space 14. As the insulating material44 is blown, poured or otherwise deposited within the insulating space14, gas 12 can simultaneously be drawn from the insulating space 14 andinto the gas conduit 40. This movement of gas 12 from the insulatingspace 14 and through the gas conduit 40 acts as a vacuum to draw fineparticulate insulating material 44 throughout the insulating space 14.Because the gas conduit 40 is spaced throughout portions of the interiorcavity 100, the fine particulate insulating material 44 can be drawn ina plurality of directions to fill or substantially fill spaces that mayexist between larger sized particles of insulating material 44.Accordingly, by using the gas conduit 40, a flow of powder insulatingmaterial 44 having a fine particle size can be drawn to fillsubstantially all areas of the insulating space 14. The use of the gasconduit 40 to draw the powder insulating material 44 throughout theinsulating space 14 also serves to provide a more densely packedinsulating material 44. This is especially true after the gas conduit 40is implemented to generate the at least partial vacuum 20 within theinterior cavity 100.

After the vacuum chamber 64 defines a first gas pressure 60 that issubstantially equal to the surrounding atmosphere, the vacuum chamber 64is separated from the structural cabinet 16 (step 418). The atmosphericpressure around the structural chamber is greater than the second gaspressure 62 within the interior cavity 100 of the structural cabinet 16,such that the gas valves 50 are maintained in the closed position 54.Accordingly, the at least partial vacuum 20 within the insulating space14 with the gas conduit 40 is maintained after the vacuum chamber 64 isseparated from the structural cabinet 16.

According to the various embodiments, the vacuum generating system 10described herein can be used for generating the vacuum insulatedstructure within the various appliances 18. These appliances 18 caninclude, but are not limited to, refrigerators, freezers, ovens, variousother appliances, vacuum insulated structures, vacuum insulated panels,and other similar vacuum-based insulation systems. It is alsocontemplated that the materials of the structural cabinet 16 can vary,where such materials can include, but are not limited to, metals,plastics, various polymers, combinations thereof and other similarmaterials. Typically, the trim breaker 26 for the structural cabinet 16will be made of plastic that is either attached to the inner liner 24and outer wrapper 22 or is injection molded around portions of the innerliner 24 and outer wrapper 22. The inner liner 24 and outer wrapper 22may be made of various rigid materials that can include, but are notlimited to, metals, plastics, combinations thereof, and other similarrigid-type materials.

It is further contemplated that the placement of the gas conduit 40,within portions of the trim breaker 26, can vary. As exemplified inFIGS. 4 and 5, the gas conduit 40 may be disposed proximate anattachment point for either one of the inner liner 24 and outer wrapper22. It is also contemplated that the gas conduit 40 may be centrallydisposed within the trim breaker 26. The exact placement of the gasconduit 40 and the gas valves 50 can vary depending upon the design ofthe appliance 18, as dictated by the various factors discussed herein.

According to the various embodiments, the use of the vacuum generatingsystem 10 allows for providing a well packed insulating material 44within the insulating space 14, particularly around the trim breaker 26where the gas conduit 40 is typically located. The well packedinsulating material 44 provides for lower thermal conductivity throughthe structural cabinet 16 and at the trim breaker 26. Maintaining alower thermal conductivity within and around the trim breaker 26 isuseful to prevent external condensation on the refrigerator walls andnear the interface between the structural cabinet and the doors andother operable panels of the appliance 18.

It will be understood by one having ordinary skill in the art thatconstruction of the described device and other components is not limitedto any specific material. Other exemplary embodiments of the devicedisclosed herein may be formed from a wide variety of materials, unlessdescribed otherwise herein.

For purposes of this disclosure, the term “coupled” (in all of itsforms, couple, coupling, coupled, etc.) generally means the joining oftwo components (electrical or mechanical) directly or indirectly to oneanother. Such joining may be stationary in nature or movable in nature.Such joining may be achieved with the two components (electrical ormechanical) and any additional intermediate members being integrallyformed as a single unitary body with one another or with the twocomponents. Such joining may be permanent in nature or may be removableor releasable in nature unless otherwise stated.

It is also important to note that the construction and arrangement ofthe elements of the device as shown in the exemplary embodiments isillustrative only. Although only a few embodiments of the presentinnovations have been described in detail in this disclosure, thoseskilled in the art who review this disclosure will readily appreciatethat many modifications are possible (e.g., variations in sizes,dimensions, structures, shapes and proportions of the various elements,values of parameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter recited. For example,elements shown as integrally formed may be constructed of multiple partsor elements shown as multiple parts may be integrally formed, theoperation of the interfaces may be reversed or otherwise varied, thelength or width of the structures and/or members or connector or otherelements of the system may be varied, the nature or number of adjustmentpositions provided between the elements may be varied. It should benoted that the elements and/or assemblies of the system may beconstructed from any of a wide variety of materials that providesufficient strength or durability, in any of a wide variety of colors,textures, and combinations. Accordingly, all such modifications areintended to be included within the scope of the present innovations.Other substitutions, modifications, changes, and omissions may be madein the design, operating conditions, and arrangement of the desired andother exemplary embodiments without departing from the spirit of thepresent innovations.

It will be understood that any described processes or steps withindescribed processes may be combined with other disclosed processes orsteps to form structures within the scope of the present device. Theexemplary structures and processes disclosed herein are for illustrativepurposes and are not to be construed as limiting.

It is also to be understood that variations and modifications can bemade on the aforementioned structures and methods without departing fromthe concepts of the present device, and further it is to be understoodthat such concepts are intended to be covered by the following claimsunless these claims by their language expressly state otherwise.

The above description is considered that of the illustrated embodimentsonly. Modifications of the device will occur to those skilled in the artand to those who make or use the device. Therefore, it is understoodthat the embodiments shown in the drawings and described above is merelyfor illustrative purposes and not intended to limit the scope of thedevice, which is defined by the following claims as interpretedaccording to the principles of patent law, including the Doctrine ofEquivalents.

What is claimed is:
 1. A method of forming a vacuum insulated structure,the method comprising steps of: coupling a trim breaker to an innerliner and an outer wrapper to define a structural cabinet and aninsulating space therein, the trim breaker defining an interior gasconduit that is at least partially separated from the insulating space;disposing an insulating material within the insulating space; attachinga plurality of gas valves to the structural cabinet, the plurality ofgas valves being in selective communication with the insulating spacevia the interior gas conduit; placing a vacuum chamber around at least aportion of the structural cabinet such that the plurality of gas valvesare disposed within the vacuum chamber; expressing gas from the vacuumchamber to define a first gas pressure proximate the exterior of thestructural cabinet and around the plurality of gas valves, the first gaspressure being less than a second gas pressure defined within theinsulating space and the interior gas conduit, thereby defining an openposition of the plurality of gas valves; expressing gas from theinsulating space through the plurality of gas valves in the openposition via the interior gas conduit and into the vacuum chamber,wherein expressed gas is further expressed from the vacuum chamber,wherein as the expressed gas is expressed through the interior gasconduit, the insulating material is maintained in the insulating space;placing the plurality of gas valves in a closed position by defining asubstantially equalized pressure within the vacuum chamber and theinsulating space, wherein the first gas pressure is approximately equalto the second gas pressure; returning gas to the vacuum chamber suchthat the first gas pressure is greater than the second gas pressure, andwherein the plurality of gas valves are maintained in the closedposition; and separating the vacuum chamber and the structural cabinet.2. The method of claim 1, wherein the vacuum chamber extends around theentire structural cabinet.
 3. The method of claim 1, wherein each gasvalve of the plurality of gas valves is an umbrella valve having anoperable flap that engages an outer surface of the structural cabinet inthe closed position, and is separated from the outer surface in the openposition.
 4. The method of claim 1, wherein the vacuum chamber is avacuum frame that selectively engages the trim breaker, wherein the stepof placing the vacuum chamber includes attaching the vacuum frame to thetrim breaker.
 5. The method of claim 4, wherein the step of attachingthe plurality of gas valves to the structural cabinet includes attachingthe plurality of gas valves to the trim breaker.
 6. The method of claim5, wherein the step of expressing gas from the vacuum chamber includesdefining a vacuum space that is formed between the vacuum frame and anouter surface of the trim breaker.
 7. The method of claim 6, wherein theplurality of gas valves are configured to be located within the vacuumspace when the vacuum frame is attached to the trim breaker.
 8. Themethod of claim 4, wherein the vacuum frame selectively engages a frontedge of the trim breaker.
 9. A method of expressing gas from aninsulated structure to form a vacuum insulated structure, the methodcomprising steps of: attaching a vacuum chamber to a surface of astructural cabinet such that a plurality of gas valves are disposedwithin a vacuum space defined between the vacuum chamber and the surfaceof the structural cabinet, wherein the plurality of gas valves areattached via an interior gas conduit within an insulating space of thestructural cabinet; expressing gas from the vacuum space to define afirst gas pressure proximate the plurality of gas valves, the first gaspressure being less than a second gas pressure defined within aninterior insulating space of the structural cabinet and the interior gasconduit, thereby defining an open position of the plurality of gasvalves; expressing gas from the insulating space through the pluralityof gas valves in the open position via the interior gas conduit and intothe vacuum space, wherein an insulating material is maintained in theinsulating space; placing the plurality of gas valves in the closedposition by defining a substantially equalized pressure within thevacuum space and the insulating space, wherein the first gas pressure isapproximately equal to the second gas pressure; returning gas to thevacuum space such that the first gas pressure is greater than the secondgas pressure, and wherein the plurality of gas valves are maintained inthe closed position; and separating the vacuum chamber and thestructural cabinet.
 10. The method of claim 9, wherein the vacuumchamber is a vacuum frame that selectively engages a trim breaker,wherein the step of placing the vacuum chamber includes attaching thevacuum frame to the trim breaker.
 11. The method of claim 10, whereinthe step of attaching the plurality of gas valves to the structuralcabinet includes attaching the plurality of gas valves to the trimbreaker.
 12. The method of claim 11, wherein the step of expressing gasfrom the vacuum chamber includes defining a vacuum space that is formedbetween the vacuum frame and an outer surface of the trim breaker. 13.The method of claim 12, wherein the plurality of gas valves areconfigured to be located within the vacuum space when the vacuum frameis attached to the trim breaker.
 14. The method of claim 10, wherein thevacuum frame selectively engages a front edge of the trim breaker. 15.The method of claim 10, wherein the interior gas conduit is incorporatedwithin the trim breaker.
 16. The method of claim 15, wherein theinterior gas conduit includes a filter member that maintains theinsulating material within the insulating space.
 17. The method of claim9, wherein each gas valve of the plurality of gas valves is an umbrellavalve having an operable flap that engages an outer surface of thestructural cabinet in the closed position, and is separated from theouter surface in the open position.
 18. A method of forming a vacuuminsulated structure, the method comprising steps of: coupling a trimbreaker to an inner liner and an outer wrapper to define a structuralcabinet and an insulating space therein, the trim breaker defining aninterior gas conduit that is at least partially separated from theinsulating space; disposing an insulating material within the insulatingspace; attaching a plurality of gas valves to the trim breaker, theplurality of gas valves being in selective communication with theinsulating space via the interior gas conduit; placing a vacuum frameagainst an exterior surface of the structural cabinet proximate the trimbreaker such that the plurality of gas valves are disposed within avacuum space defined between the vacuum frame and the trim breaker;expressing gas from the vacuum space to define a first gas pressureproximate the exterior of the trim breaker and around the plurality ofgas valves, the first gas pressure being less than a second gas pressuredefined within the insulating space and the interior gas conduit,thereby defining an open position of the plurality of gas valves;expressing gas from the insulating space through the plurality of gasvalves in the open position via the interior gas conduit and into thevacuum space, wherein expressed gas is further expressed from the vacuumframe, wherein as the expressed gas is expressed through the interiorgas conduit, the insulating material is maintained in the insulatingspace; placing the plurality of gas valves in a closed position bydefining a substantially equalized pressure within the vacuum space andthe insulating space, wherein the first gas pressure is approximatelyequal to the second gas pressure; returning gas to the vacuum space suchthat the first gas pressure is greater than the second gas pressure, andwherein the plurality of gas valves are maintained in the closedposition; and separating the vacuum frame from the structural cabinet.19. The method of claim 18, wherein each gas valve of the plurality ofgas valves is an umbrella valve having an operable flap that engages anouter surface of the structural cabinet in the closed position, and isseparated from the outer surface in the open position.
 20. The method ofclaim 18, wherein the vacuum frame selectively engages a front edge ofthe trim breaker.